Automated Sensor Testers

In the complex and demanding world of industrial automation and quality control, the reliability of a sensor is not just a feature—it is a critical necessity. Sensors are the eyes and ears of a system, providing the essential data that drives control, safety, and efficiency. Yet, ensuring their consistent performance, both at the end of a production line and during warranty analysis in the lab, presents a significant challenge. Manual testing is often slow, inconsistent, and unable to replicate the precise, multi-faceted conditions a sensor will face in the field. Recognizing this critical gap, Kadronics introduces its cutting-edge Automated Sensor Testers, a solution meticulously engineered to provide uncompromising accuracy, speed, and reliability.

Our Automated Sensor Testers are designed to serve two primary, yet distinct, use cases with equal proficiency: industrial End of Line (EOL) Testing and Laboratory Warranty Analysis. For EOL testing, our system offers a robust, high-speed verification process that ensures every sensor leaving your facility meets stringent quality standards. In a laboratory setting, it provides a powerful diagnostic tool for analyzing sensor failures, allowing for precise, reproducible testing that helps pinpoint the root cause of a defect and improve future designs. While each system is modified for different types of sensor specifications, the core architecture is a testament to our engineering excellence, ensuring a scalable and flexible platform for all your testing needs.

At the heart of our solution is the advanced 10″ HMI (Human-Machine Interface). This intuitive and responsive touchscreen serves as the central command hub, providing operators with a clear, real-time view of the testing process. The HMI simplifies complex test routines, allowing for easy selection of test parameters, monitoring of live data, and quick analysis of results. Its user-friendly design reduces the learning curve for new operators and minimizes the risk of human error, which is a common issue in manual testing. This interface is more than just a screen; it is a gateway to precision control, enabling seamless interaction with every component of the testing process.

The power behind the operation is our integrated PLC (Programmable Logic Controller) Controls. This industrial-grade control system ensures that every test is executed with the highest level of precision and repeatability. The PLC manages the sequential logic of the testing process, from activating specific test environments to recording sensor responses with microsecond accuracy. It provides a stable and reliable foundation for even the most demanding test cycles, guaranteeing that the conditions for each sensor are identical, regardless of the time of day or the operator. This robust control system is the key to achieving the reproducible results that are essential for both quality control and defect analysis.

A standout feature of our tester is the Built-in Tank, a component that allows for the creation of a dynamic and controlled liquid environment. This is a critical capability for testing Level Sensors and Flow Sensors, as it enables our system to simulate real-world conditions with unparalleled accuracy. We can precisely control the fluid level and flow rate, testing a sensor’s ability to perform under a variety of conditions, from steady states to rapid changes. This built-in tank eliminates the need for separate, bulky test rigs and integrates fluid control directly into the system, streamlining the testing process and saving valuable floor space. The system’s ability to handle fluids also extends to its support for Pressure Sensors, where it can apply and control precise levels of pressure to validate a sensor’s output across its entire operating range.

The versatility of our system is further highlighted by its ability to test a wide range of sensor types. Beyond fluid-based sensors, our system is expertly configured for Humidity Sensors. We can create and maintain controlled humidity environments, allowing for the precise calibration and validation of a sensor’s response to varying moisture levels. This is especially vital for products used in sensitive applications, such as climate control systems or environmental monitoring. The comprehensive nature of our tester, accommodating a broad spectrum of sensor technologies, makes it a true all-in-one solution for manufacturers with a diverse product portfolio.

Crucially, the Kadronics Automated Sensor Tester is a powerful tool for data-driven decision-making. The system’s advanced Data logging and Data Analysis capabilities are second to none. Every test parameter, every sensor response, and every pass/fail result is meticulously recorded and time-stamped. This rich dataset can be easily exported for further analysis, allowing engineers to identify trends, pinpoint design weaknesses, and optimize production processes. The data provides a complete, traceable history for every single sensor, a necessity for industries with strict quality and regulatory standards. For warranty analysis, this data is invaluable, providing the objective evidence needed to diagnose a sensor failure and inform future product improvements.

In conclusion, the Kadronics Automated Sensor Tester is the ultimate solution for companies that cannot afford to compromise on quality. It is a sophisticated, reliable, and highly flexible system that provides the precision and repeatability needed for today’s complex sensor technologies. By combining a user-friendly HMI with robust PLC controls, a versatile built-in tank, and comprehensive data management, our tester streamlines the entire verification process, from the end of the production line to the laboratory. It is an investment in quality assurance, risk reduction, and operational excellence, ensuring that your sensors—and the systems they control—perform flawlessly every time.